What is Aseptic Packaging Made Of? 

Posted by Hammad

The world right now is suffering from a deadly pandemic due to unhygienic living styles in the past. Now, people are adopting healthy lifestyles to keep themselves safe and healthy. From their food to their clothes, they demand health assurance. Aseptic packaging, therefore, is highly appreciated by the customers because this type of packaging keeps the product safe from microbial attacks and severe atmospheric conditions.

Aseptic packaging: 

aseptic packaging example

Microorganisms are prevented from entering a product during and after packing by using aseptic packaging. A sterilized package is filled with a commercially sterile food product and sealed inside the constraints of a sanitary environment during aseptic processing.

Aseptic packaging is used for a variety of food and beverage goods, including milk, soup, tomatoes, pudding, and many more. It’s also utilized in the pharmaceutical sector to guarantee that drugs don’t get contaminated with dangerous microbes.

Hydrogen peroxide sterilization, followed by hot air, is the most frequent technique employed. For sterilizing packing materials, businesses are moving away from chemical techniques and toward non-thermal technologies including light pulses, UV laser light, electron beams, and plasma discharge.

Composition of aseptic packaging: 

To meet aseptic packaging criteria, many components are stacked together, including:

  • The inside and exterior surfaces of aseptic packaging are both lined with polyethylene as a barrier. Moisture cannot enter or leave the container through these layers.
  • By keeping light and oxygen out, film foil aids in product preservation.

While the carton is the most common aseptic packaging, pouches, cups, trays, and plastic cans are also used.

Aseptic packaging is typically composed of:

  • Paper (70%)
  • Polyethylene (LDPE) (24%)
  • Aluminum (6%)
  • An inside tight layer of polyethylene

Filling and closing a sterile packing material with a sterilized product is what aseptic packaging is all about. Due to the lower cost of creating plastic material compared to metal and glass, the majority of the aseptic packing material is composed of plastics rather than metal or glass containers.

In conventional aseptic packing, paper and plastic are commonly utilized. Aside from that, aseptic packaging may be done with foil, metal cans, and different metal containers. This diverse selection of packing materials boosts efficiency while lowering costs.

Aseptic packaging may be divided into two types:

  • Direct (steam infusion and steam injunction)
  • Indirect (steam infusion and steam injunction) (comprises scraped surface heat exchanger, plate heat exchanger, and tubular heat exchanger).

Because the steam injection is a quicker procedure, some volatile is wasted, but steam infusion allows for more precise control of the processing conditions, reducing the risk of food overheating.

A special need of plastic for aseptic packaging: 

Because plastics play such an essential role in aseptic packing, it’s worth talking about some of the unique qualities that the aseptic process requires of them. Chemical and wettability resistance, thermal stability, low quantities of infecting microbes, and ionizing radiation resistance are some of them.

Importance of aseptic packaging: 

For all homes, medicine and food are necessary things. We can be confident in the safety and health standards of the goods we come across and consume daily thanks to the aseptic packaging process.

The word “aseptic” comes from the Greek word “septicos,” which means “without dangerous or putrefactive bacteria.” External hazards such as microbial assaults or exposure to gases that might taint food items are protected by food packaging.

Although aseptic packaging has been available since the 1960s, it continues to be important now and in the future, satisfying customers’ expectations for value and quality food items on the go that match their busy lifestyle.

Increasing demand for Aseptic Packaging: 

According to research by the Freedonia Group, pharmaceuticals had the largest market for aseptic packaging in 2015, accounting for 61% of the overall demand in the US. However, aseptic packaging for food and beverage has experienced an increase in popularity in recent years, and demand for it continues to grow.

Aseptic packaging accounted for $40 million in revenue in 2017. With rising demand from quickly developing countries and tighter government restrictions on food processing, the sector is anticipated to rise year after year.

According to research released by Fior Markets, the market is expected to expand from $38.16 billion in 2019 to $81.22 billion in 2027, rising at a CAGR of 9.9%.

This increase can be linked to customers’ changing lifestyles in emerging nations, which has resulted in higher demand for ready-to-eat foods. As a result of a movement in customer choice away from the usage of food preservatives, the aseptic packaging industry has seen rising demand.

Top benefits of Aseptic Packaging: 

Aseptic packaging increases the shelf life:

Aseptic packing extends the shelf life of certain foods for at least 6 to 12 months even when they are not refrigerated. Manufacturers and merchants have more time to sell their products before they expire or lose their flavor and health advantages with a longer shelf life. Consumers benefit from longer expiry dates since they have more time to keep and eat their purchases, even at room temperature.

No need for preservatives: 

Aseptic packaging’s cutting-edge sterilization method protects products from germs, allowing for the use of more natural components and the elimination of additives. Manufacturers will be able to fulfill customer demand for a cleaner ingredient list that is devoid of chemicals and preservatives.

Aseptic packaging maintains the quality of the product:

Because it helps preserve the taste and general quality of food items, the aseptic packaging technique is used to meet consumer demand for nutrient-dense foods. Food in aseptic packaging retains its flavor, fragrance, and nutritional value, guaranteeing buyers of the product’s quality.

In the pharmaceutical sector, aseptic packaging is even more important for maintaining perfect sterility and keeping medical devices and medications free of contamination.

Aseptic packaging is eco-friendly:

Manufacturers utilize the aseptic packing technique as a long-term solution that helps them meet their environmental goals. The packaging consists largely of renewable materials like paper and cartons, which significantly minimizes the usage of plastic. Some firms employ carbon-neutral, 100 percent recyclable eco-friendly packaging in response to the industry’s need for sustainability. This type of packaging is likely to appeal to environmentally conscious consumers seeking authenticity in their product purchases.

Aseptic packaging reduces the cost of distribution and shipping:

In comparison to most other forms of packaging, aseptic packaging uses lighter materials. Polyethylene, which protects the product by preventing moisture from entering and exiting the container, and film foil, which keeps light and moisture out, are two materials used in aseptic packaging.

These lightweight and protective materials assist to minimise transportation weight and lessen the need to refrigerate items that need to be kept cool throughout distribution. As a result of these variables, producers can reduce transportation and distribution expenses.

When opposed to hot fill and retort processing, aseptic packaging uses a gentler processing procedure at lower temperatures. Gentler processing preserves the flavor, texture, appearance, and health advantages of foods that may be lost in hotter processing procedures. The processing time is frequently reduced, allowing firms to get items to market faster.

The primary benefit of aseptic packaging over hot fill or retorting is that by employing high-temperature short-time sterilization, the food product is exposed to heat for a significantly shorter period, preventing the loss of important nutrients and tastes. Furthermore, the use of aseptic packaging lowers storage and shipping costs [no refrigeration necessary], increases sales by extending product shelf life to 12 months, and saves energy by recovering up to 80% of heat exchanger energy.

Benefits in logistics: 

A one-liter beverage carton weighs only 28 grams, compared to up to 380 grams for a glass container. Lower storage costs, increased warehouse efficiency, good stackability, improved pallet usage design, and empty goods are kept flat until ready to use (unlike glass or cans). Only 150, 000 glass bottles may be transported in a typical semi-trailer vehicle. When fully loaded, it saves space in shipment. More merchandise may be piled in the truck because of the brick form.

Applications of aseptic packaging: 

There are primarily two fields to consider: Pre-sterilized and sterile product packaging is the first field. Milk and dairy products, puddings, sweets, fruit and vegetable juices, soups, sauces, and particulate-containing goods are all included in this category. Second, to prevent microorganism contamination in non-sterile products during packaging. Fermented dairy products, such as yogurt, are an excellent example.

Milk aseptic packaging: The “Tetra-pack” system was first created in Sweden to package aseptic or long-life milk. It necessitates the use of a laminate pre-sterilizer as well as a filling environment heater. Aluminum foil is a crucial component of the flexible laminate because it acts as a light and gas barrier. Milk is warmed to 73–850°C, then rapidly increased to 135°C for a fraction of a second before being flashed into a vacuum chamber to cool. It must be packaged in a sanitary environment. For at least 3-6 months, no refrigeration is required.

Shelf life of up to one year is achievable if kept refrigerated. The pouches are kept in reusable multi-trip plastic crates in the delivery system. Tetra Pak aseptic cartons are made up of three fundamental components that work together to create highly efficient, safe, and light packaging. Each substance has a distinct purpose. Aseptic containers can range in size from a few fluid ounces to an ocean-going ship’s approximately 8-million-gallon septic tank. Aseptic processing is used to export and import innovative, cost-effective, and safe food items all over the world. Drink boxes and pouches are two more frequent packaging kinds.

Aseptic packaging is a safe and high-quality packaging solution that has been used in food service applications all over the world. Aseptic processing sterilizes food by destroying harmful bacteria and pathogenic microorganisms through a carefully controlled thermal process, then combining the sterile product with sterile packaging material in a sterile environment; the result is a shelf-stable product that does not require refrigeration.

The extended shelf-life, excellent seal integrity, and consumer appeal requirements for aseptic packaging were very stringent. The use of plastics in aseptic packaging primarily extends the non-refrigerated shelf life and necessitates the purchase of numerous perishable goods. This is now largely utilized in the package’s innermost touch layers to safeguard food quality. Wine, soup, baby food, and water products have all been packaged aseptically in recent years.

Characteristics of Aseptic packaging: 

The low water-vapor transfer rate is a characteristic of aseptic packing. Gas transmission rates are low, particularly when it comes to oxygen. This is important for preserving the food’s color, taste, and nutritional components. Physical or mechanical strength is sufficient to withstand any physical harm during manufacturing, handling, and distribution. Ability to operate in automatic fabrication and filling equipment and good sealing properties to prevent the entry of external contaminants. Temperature resistance during filling, storage, and distribution of the product.

Chemically resistant to the packed product and able to withstand sterilizing packing material using a gas or liquid radiation. Microbes, insects, and other biological threats require resistance. Compatibility with the milk that has been stored. In line with the country’s appropriate codes of practice and standards, the packaging material’s ingredients, additives, and other components should be inert with minimal migration levels. When compared to packaged products, it is less expensive and more readily available.

Aseptic packaging by Custom Crating and Logistics: 

Custom Crating and Logistics provide aseptic packaging for the maintenance of the hygiene of the product. Our company provides aseptic packaging for medical products and various preserved products so that they would not be harmed by any bacterial attack. When all packing materials are packed, our aseptic procedure guarantees that they are free of dangerous germs. Every step of the manufacturing process must be commercially sterile. This covers packaging materials, machinery, and the packaging environment. ​​

We provide services across Chicago and various other parts of United States. Our company ensures complete freight security and assurance of clearance. Our team can help you with various logistic services in EIk Grove Village, IL. We provide various services like ground freight, crating, industrial packing, storage, and many more.

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